Diffuser and solids collection and measurement system for use in conjunction with oil and gas wells

ABSTRACT

A diffuser and solids collection system includes a first baffle section having an input for receiving from a petroleum well a fluid carrying solids and a first set of internal baffles for reducing a velocity of the fluid. A second baffle section in fluid communication with the first baffle section has a second set of internal baffles for further reducing the velocity of the fluid. A solids collection container separates the solids from the fluid received from the second baffle section. A weighing system, supported by the second baffle section and supporting the solids collection container, weighs the solids collected in the solids collection container.

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims the benefit of U.S. Provisional PatentApplication Ser. No. 62/680,995, filed Jun. 5, 2018, which isincorporated herein in its entirety for all purposes.

FIELD OF INVENTION

The present invention relates in general to oil and gas operations andin particular to a diffuser and solids collection and measurement systemfor use in conjunction with oil and gas wells.

BACKGROUND OF INVENTION

In a typical oil well, the oil, gas, water, and solids are produced atthe wellhead and then separated. The oil, gas, and usable amounts ofwater are sent for sale or reuse. The solids, which may include solidssuch as fracing proppants (e.g., frac sand), are sent to a solids tankfor recovery.

In many instances, the amount of solids being output from a given wellor group of wells must be monitored. Current methods are based on roughestimates made by personnel observing the output being discharged intothe tank. And while it would be advantageous to provide a more accurateand efficient method of determining the amount of solids being producedby a well, the nature of wellhead operations presents some significantchallenges for achieving that goal. For example, the solids-bearingwater is typically produced under pressure and is therefore dischargedit at a high velocity.

SUMMARY OF INVENTION

The principles of the present invention are embodied in a diffuser andsolids collector system that provides for the collection of solidsdischarged from a wellhead and the accurate measurement (e.g., weighing)of the collected solids.

One particular embodiment of these principles is a diffuser and solidscollection system, which includes a first baffle section having an inputfor receiving from a petroleum well a fluid carrying solids and a firstset of internal baffles for reducing a velocity of the fluid. A secondbaffle section in fluid communication with the first baffle section hasa second set of internal baffles for further reducing the velocity ofthe fluid. A solids collection container separates the solids from thefluid received from the second baffle section. A weighing system,supported by the second baffle section and supporting the solidscollection container, weighs the solids collected in the solidscollection container.

Advantageously, the principles of the present invention allow for anaccurate measurement of the solids flowing out of a petroleum well underpressure.

BRIEF DESCRIPTION OF DRAWINGS

For a more complete understanding of the present invention, and theadvantages thereof, reference is now made to the following descriptionstaken in conjunction with the accompanying drawings, in which:

FIG. 1 depicts a representative petroleum well serviced by a diffuserand solids collector system according to the principles of the presentinvention;

FIG. 2A is a perspective view of an exemplary embodiment of the diffuserand solids collector system FIG. 1, embodying the principles of thepresent invention, and as installed over the solids collection tank ofFIG. 1;

FIG. 2B is a side elevational view of the diffuser and solids collectorsystem of FIG. 2A;

FIG. 3 is a perspective view of the diffuser and solids collector systemof FIG. 2A;

FIG. 4A is partial cutaway end view of the diffuser and solids collectorsystem of FIG. 2A showing the internal baffles of the vertical bafflesection;

FIG. 4B is a cutaway top view of the diffuser and solids collectorsystem of FIG. 2A showing the internal baffles of the vertical bafflesection;

FIG. 5 is a cutaway top view of the diffuser and solids collector systemof FIG. 2A showing the internal baffles of the horizontal bafflesection;

FIG. 6A is a side view of the solids collection box of the diffuser andsolids collector system of FIG. 2A;

FIG. 6B is a top view of the solids collection box of the diffuser andsolids collector system of FIG. 2A without the bottom release handle inplace;

FIG. 6C is a top view of the solids collection box of the diffuser andsolids collector system of FIG. 2A with the bottom release handle inplace;

FIG. 6D is a top perspective view of the solids collection box ofdiffuser and solids collector system of FIG. 2A showing the bottomrelease mechanism; and

FIG. 7 is a side view of the diffuser and solids collector system ofFIG. 2A showing the weighing system in further detail.

DETAILED DESCRIPTION OF THE INVENTION

The principles of the present invention and their advantages are bestunderstood by referring to the illustrated embodiment depicted in FIGS.1-7 of the drawings, in which like numbers designate like parts.

FIG. 1 is a diagram of an exemplary petroleum well system including adiffuser and solids collector system 100 embodying the present of thepresent invention. FIG. 1 shows three (3) petroleum production wells 101a-101 c, corresponding water/solids separators 102 a-102 f, valve manualmanifolds 103 a-103 c, four-phase separators 104 a-104 c, solids tank105, and open top tank 106. In other systems, the manifolds may be chokemanifolds and the separators 2- or 3-phase separators.

Solids-bearing water from water/solids separators 102 a-102 f and fourphase separators 104 a-104 c are passed to diffuser and solids collectorsystem 100. As discussed in further detail below, the water bearingsolids, such as frac sand, are delivered diffusor and solids collectionsystem 100, which reduces the fluid velocity, collects the solids, andallows the solids to be weighed. Once a desired amount of solids havebeen collected an weighed, they are discharged from diffuser and solidscollector system 100 into solids tank 105.

FIG. 2A partially shows a preferred embodiment of diffuser and solidscollection system 100 mounted on the solids tank 106 of FIG. 1. FIG. 2Bshows the exterior of diffuser and solids collector system 100 infurther detail. The illustrated embodiment includes a vertical bafflesection 201, a horizontal baffle section 202, and a particulate (solids)collection box 203, which is supported by a scale 204 and pyramidsupport structure 205.

High-velocity solids-bearing water is received through an inlet 206 nearthe top a vertical baffle section 201 and passes through a series ofinternal baffles, discussed in further detail below. Additional baffleswithin contiguous horizontal baffle section 202 further reduce the fluidvelocity.

After the reduction in fluid velocity, the solids-bearing water isdischarged through an aperture in the base of horizontal baffle section202 and into particulate collection box 203. Particulate collection box203 includes filter material supported by a hinged screen on the base.The hinged screen is associated with a handle and release mechanism,which allow a lateral edge of the hinged screen to be released and thecollected solids to be dumped into solids tank 105 below, once thosesolids have been weighed by scale 204.

FIG. 3 provides an alternate view of diffuser and solids collectorsystem 100. Vertical baffle section 201 includes vents 207 on opposingsides for discharging gases accumulated during the diffusion process.The upper surface of the horizontal baffle section 202 includes anaperture through which a turnbuckle extends, as discussed below, tocouple scale 204 with particulate collection box 203. Supports 302 atthe four corners are provided for supporting diffuser and solidscollector system 100 on the walls of solids tank 105 during use. Hinges300 a-300 c allow a portion of the upper surface of horizontal bafflesection 202 to swing open for internal access.

FIGS. 4A-4B show the preferred vertical baffle section 201 in furtherdetail. As shown in FIGS. 4A and 4B, three (3) elongated internalrectangular baffles 400 a-400 c are provided near the top of verticalbaffle section 201, along with two (2) slanted planar baffles 401 a-401b extending from opposing sidewalls. (The principles of the presentinvention are not limited to this configuration, and in alternateembodiments, the number of rectangular and/or slanted baffles, as wellas their positioning, may vary. In addition, the number and location ofvents 207 and fluid inlet 206 may also vary in alternate embodiments.)

A preferred configuration of horizontal baffle section 202 is shown inFIG. 5. In the embodiment, four (4) baffles 500 a-500 d extend upwardfrom the angled side-sections 502 a-502 b of the floor and at an angleto the horizontal baffle section 202 lateral sidewalls. A rectangularbaffle 501 extends upward from the flat portion 503 of the floor andperpendicular to the lateral sidewalls. In alternate embodiments, thenumber and configuration of the baffles of the horizontal baffle section202 may vary. Aperture 502 through the floor allows a turn buckle toextend through the interior of horizontal baffle section 202 forcoupling particulate collection box 203 with scale 204, as well as toallow solid-bearing water to discharge into particulate collection box203.

FIGS. 6A-6D illustrate the preferred configuration of particulatecollection box 203. The bottom of the solids collection box is a hingedscreen 600 as shown in FIG. 6A. A crossbar 602, as shown in FIG. 6B,provides structural support, as well as a grasping point for theturnbuckle hook. Four (4) vents 601 a-601 d are provided for discharginggas (FIG. 6B).

As shown in FIG. 6C, filter material 603 is disposed across hingedscreen 600 for capturing solids as water is discharged through thebottom of particulate collection box 203 into solids tank 105. Once thesolids have been collected and weighed, hinged screen 600 is releasedusing the release mechanism of FIG. 6D.

The release mechanism includes a release handle 604 and a rotating latch605, which includes a slot 607 for engaging a pin 606 extending from thefree (non-hinged) side of hinged screen 600. Rotation of the latcharound pivot point 608 is controlled by handle 604. When hinged screen600 is the closed position, pin 606 on hinged screen 600 slides intoslot 607 of rotating latch 605. To release hinged screen 600, and allowthe free edge to fall, handle 604 is rotated such that latch 605 rotatesaway from pin 606 and pin 606 exits slot 607 in the latch 605.

The weighing system is shown in FIG. 7 for the preferred embodiment ofdiffuser and solids collector system 100. A pyramid support is disposedon the upper side of the horizontal baffle section. As discussed above,pyramid support 205 supports a scale 204. A turnbuckle 700, which iscoupled to scale 704 by a hook 702, extends through aperture 301 on theupper surface of horizontal baffle section 202 and aperture 502 throughthe floor of horizontal baffle section 202. An opposing hook 701 couplesto crossbar 602 of particle collection box 203. The solids captured byparticulate collection box 203 and particulate collection box 203 itselfare weighed together and the tare taken to determine the weight of thesolids alone.

The primary components of diffuser and solids collector system 100including vertical baffle section 201 and internal baffles 400 and 402,horizontal baffle section 202 and internal baffles 500 and 501, andparticulate (solids) collection box 203, are preferably fabricated fromsteel. In alternate embodiments, other materials capable of withstandingthe stresses from use of diffuser and solids collector system 100 in thepetroleum fields may be used.

Although the invention has been described with reference to specificembodiments, these descriptions are not meant to be construed in alimiting sense. Various modifications of the disclosed embodiments, aswell as alternative embodiments of the invention, will become apparentto persons skilled in the art upon reference to the description of theinvention. It should be appreciated by those skilled in the art that theconception and the specific embodiment disclosed might be readilyutilized as a basis for modifying or designing other structures forcarrying out the same purposes of the present invention. It should alsobe realized by those skilled in the art that such equivalentconstructions do not depart from the spirit and scope of the inventionas set forth in the appended claims.

It is therefore contemplated that the claims will cover any suchmodifications or embodiments that fall within the true scope of theinvention.

What is claimed is:
 1. A diffuser and solids collection systemcomprising: a first baffle section having an input for receiving from apetroleum well a fluid carrying solids and a first set of internalbaffles for reducing a velocity of the fluid; a second baffle section influid communication with the first baffle section and having a secondset of internal baffles for reducing the velocity of the fluid; a solidscollection container in fluid communication with the second bafflesection for separating the solids from the fluid received from thesecond baffle section; and a weighing system supported by the secondbaffle section and supporting the solids collection container forweighing the solids collected in the solids collection container.
 2. Thesystem of claim 1, wherein the first set of baffles of the first bafflesection comprises a plurality of vertically spaced-apart bafflessupported by sidewalls of the first baffle section.
 3. The system ofclaim 2, wherein plurality of vertically spaced-apart baffles of thefirst baffle section comprise a first angled baffle extending downwardfrom a first sidewall and a second angled baffle extending downward froma second opposing sidewall.
 4. The system of claim 2, wherein theplurality of vertically spaced-apart baffles of the first baffle sectioncomprise a plurality of laterally spaced apart vertically alignedbaffles extending between first and second opposing sidewalls of firstbaffle section.
 5. The system of claim 1, wherein the second set ofbaffles of the second baffle section comprises a plurality of laterallyspaced baffles extending upward from a floor of the second bafflesection.
 6. The system of claim 5, wherein the plurality of laterallyspaced baffles extending upward from a floor of the second bafflesection comprise at least one baffle extending inward at an angle to asidewall of the second baffle section.
 7. The system of claim 5, whereinthe plurality of laterally spaced baffles extending upward from a floorof the second baffle section comprise at least one baffle disposedsubstantially perpendicular to a sidewall of the second baffle section.8. The system of claim 1, wherein the solids collection containercomprises: a hinged screen forming a bottom of the solids collectioncontainer; and a latching mechanism for latching the hinged screen in aclosed position during the collection of the solids and releasing thehinged screen to discharge the collected solids from the solidscollection container.
 9. The system of claim 1, wherein the weighingsystem comprises: a support structure supported by an upper surface ofthe second baffle section; a scale supported by the support structure;and a coupling mechanism coupled to the scale and extending throughapertures through upper and lower walls of the second baffle section tocouple with the solids collections container.
 10. A solids measurementsystem for measuring solids discharged from a petroleum well comprising:a vertical baffle section having an input for receiving from a petroleumwell a fluid carrying solids and a set of vertically spaced internalbaffles for reducing a velocity of the fluid; a horizontal bafflesection having a set of horizontally spaced internal baffles forreducing the velocity of the fluid discharged from the vertical bafflesection; a solids collection container for separating the solids fromthe fluid discharged from the horizontal baffle section; and a weighingsystem for weighing the solids collected in the solids collectioncontainer.
 11. The system of claim 10, wherein the solids collectioncontainer comprises: a hinged screen forming a bottom of the solidscollection container; and a latching mechanism for latching the hingedscreen in a closed position during the collection of the solids andreleasing the hinged screen to discharge the collected solids from thesolids collection container.
 12. The system of claim 11, furthercomprising a filter material disposed across the hinged screen forseparating the solids from the fluid.
 13. The system of claim 10,wherein the weighing system comprises: a support structure supported byan upper surface of the horizontal baffle section; a scale supported bythe support structure; and a coupling mechanism coupled to the scale andextending through apertures through upper and lower walls of thehorizontal baffle section to couple with the solids collectionscontainer.
 14. The system of claim 13, wherein the coupling mechanismcomprises a turnbuckle.
 15. The system of claim 10, wherein the set ofvertically spaced internal baffles of the vertical baffle sectioncomprise at least one angled baffle extending downward from a sidewallof the vertical baffle section.
 16. The system of claim 10, wherein theset of horizontally spaced internal baffles of the horizontal bafflesection extend upward from a floor of the horizontal baffle section. 17.The system of claim 10, wherein at least part of the vertical bafflesection is fabricated from steel.
 18. The system of claim 10, wherein atleast part of the horizontal baffle section is fabricated from steel.19. The system of claim 10, wherein at least part of the solidscollection container is fabricated from steel.
 20. A method of measuringsolids discharged from a petroleum well comprising: receiving from apetroleum well a fluid carrying solids; reducing a velocity of the fluidwith a vertical baffle section having a set of vertically spacedinternal baffles; reducing the velocity of the fluid discharged from thevertical baffle section with a horizontal baffle section having a set ofhorizontally spaced internal baffles; separating the solids from thefluid discharged from the horizontal baffle section with a solidscollection container supported by the horizontal baffle section; andweighing the solids collected in the solids collection container with aweighing system supported by the horizontal baffle section.